General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

PriusPlus-Electrical

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Revision as of 04:30, 24 December 2006 by Cewert (talk | contribs) (Added more categories and tips for safe battery handling)
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Click show for a short list of the current PHEV conversion and kit options for the Toyota Prius.

For Prius conversion details see the Prius PHEV article and comparisons table.

  1. Ron's Original PriusPlus History and current Contactor Based PriusPlus documentation for DIY projects.
  2. Ryan's PriusBlue is the testbed for DC-DC PFC Based PiPrius kits and documentation for DIY projects.
  3. Toyota OEM Prius PHEV and Prime Could use some work on this page
  4. Enginer China. But the rest of these appear to all be defunct as of 2020?
  5. |~- Hybrids-Plus USA/Colorado/Li -~|~- EnergyCS USA -~|~- Hymotion USA/Canada -~|~- Amberjac UK. -~|~- EDrive USA -~| Peter mentioned Plug-In Conversions |~-

--={ Project Overview }={ 2007 Maker Faire }={ Theory }={ Instructions }={ Parts List }={ RawData }={ Latest News }=--
--={ Doc Process }={ Mechanical }={ Electrical }={ Electronic }={ Interest }={ Talk:PriusPlus Main Discussion }=--

--={ Historic }={ Battery }={ Schematics }={ PseudoCode }={ Photos }=--

Team Photo from the PriusPlus conversion of Sven's Prius from Nov 2006.

This is the home of the PRIUS+ PHEV DIY (Do-it-Yourself) documentation. These pages are currently anonymously editable, which may change in the future. Please feel free to use the Discussion page for general discussion and commentary on the main article. If you would like to add to an existing section use the "edit" link near that topic's heading. Don't forget to use the Summary field to describe your changes. While editing use the "Show Preview" button to make sure your changes look like you expect them to, before you click "Save Page".



These are the high power schematics from the latest PriusPlus conversion.



Intro Paragraph here maybe with a link to the main PriusPlus article, links to external sites can appear as formatted CalCars, just plain URLs like http://www.calcars.com, or fancy references such as that in the next paragraph.

Another Paragraph and such, you can get help at our Help:Contents#How do I use the Wiki Website page <ref>http://en.wikipedia.org/wiki/Help:Contents more help using the wiki.</ref> Feel free to simply remove or if you like move all of this example text to the pages discussion article.

Electrical Parts List and Descriptions

  • Wire/cable construction
  • Part list with photos P10385.JPG We need to cut down picture to make smaller and add contrasting labels with pointers that show up well to identify parts.
    • ABS Plastic (need to enter size)
    • Muffin fans (3)
    • Contactors (2)
    • Hall sensor (1)
    • Shunt (1)
    • Shunt (1)
    • Diode(1)
    • Heat sink for Diode (1)
    • 60 amp 300 vdc fuses (2)
    • Terminal strip (1)
  • Routing
  • Connections

Electrical Parts Pre-installation

Assembly of Control Circuit Board

=Parts Needed

  • CalCars printed circuit board

Connecting the batteries

Batteries can be dangerous and can cause serious injury or death and should only be worked on by persons qualified to do so. Both energy hazards from arcs (shorts) and electrical shock can cause serious injury or be fatal with a battery pack of this size. Battery packs are always live and cannot be shut off! The following are safety tips to help prevent arcs and shocks, but they are only tips and should not be taken as a go-ahead to perform work on battery packs. Extreeme caution must be taken as it is very easy to accidently set something on the battery without thinking or drop something and cause a shock or arc. Hire a qualified electrician to help for this part if there is any doubt.

  • Remove all jewelry, especially gold, before working with batteries.
  • Do not allow metal to come into contact with the batteries that could cause an arc (best practice is to not allow any metal near the battery at all.
  • Use only fully insulated tools around batteries, especially in tight spaces (available in the electrical department in most hardware stores.)
  • When wiring batteries, be sure the other end of the wire will not accidentally come into contact with any other part of the battery or metal frames. Taping or otherwise protecting the ends of wires is recommended.
  • Wear rated rubber electricians gloves and outer protective gloves. Electricians gloves are not fail-proof and every effort should be made to only touch insulated tools even when wearing gloves.
  • If electrician gloves aren't used, only one hand should be used so that a shock will not pass current through the heart.
  • Always wear gloves when working on batteries (preferably rubber.)
  • Install the jumpers in 48 volt sections and then connect those smaller sections together at the very end. This way voltages higher than 48 volts are only handled when installing 4 jumpers instead of 16.
  • Even though the batteries are sealed, it is still possible for them to leak and splatter acid, especially if they are just charged, heated or an arc occurs. If a leak occurs, use baking soda to neutralize the acid and properly dispose. Eye protection is a good idea.
  • Orient batteries in the tray to avoid terminal contact with any bolts or any metal peices.


Electrical Final Placement and Connections

References

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